Surface display units with opaque screen

ABSTRACT

A surface display unit incorporates an opaque screen and an image panel. The opaque screen is disposed on the front side of the image panel which provides an optical image. The opaque screen generally hides the image panel while the surface display unit is not in use. When the image panel is activated to provide an optical image, the opaque screen provides a suitable level of transparency so that a viewer can observe the optical image with sufficient clarity. The opaque screen can provide optical enhancement, decorative texture, and/or mechanical support.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application and claims the benefit ofpriority under 35 U.S.C. § 120 to U.S. application Ser. No. 15/572,346,filed May 10, 2016, which claims the benefit of priority under 35 U.S.C.§ 365 of International Patent Application Serial No. PCT/US2016/031602filed on May 10, 2016, which in turn claims the benefit of priorityunder 35 U.S.C. § 119 of U.S. Provisional Application Ser. No.62/169,663 filed on Jun. 2, 2015, U.S. Provisional Application Ser. No.62/159,682 filed on May 11, 2015 and U.S. Provisional Application Ser.No. 62/159,477 filed on May 11, 2015, the contents of which are reliedupon and incorporated herein by reference in their entirety.

FIELD

The present disclosure relates generally to the field of surface displayunits and specifically to surface display units employing an opaquescreen.

BACKGROUND

Surface display units are devices that display images, signs, symbols,and/or messages as needed. Surface display units may be configured todisplay a predefined shape, word, symbol, message, and/or image, forexample. Examples of such surface display units include warning lightson a stove when the surface temperature of a heating unit is hot,warning lights for indicating low fuel status or unbuckled seat belt onan automobile, traffic or crosswalk lights on roads, and so on.Alternately, a surface display unit may be configured to display aselected display content out of many possibilities. Typically, suchsurface display units are multipixel display devices, i.e., displaydevices employing multiple pixels. The mechanism for providingillumination in multipixel display devices may include light emittingdiodes (including organic light emitting diodes) and liquid crystaldisplays. Products employing multipixel display devices include computermonitors, television sets, screens of portable digital devices, and soon.

Surface display units typically need to be mechanically protected inorder to prevent accidental damage. The need to provide protection tosurface display units may be greater for surface display units that aresubjected to mechanical impact and/or temperature extremes. For example,inside surfaces of automobile (such as the dashboard, door panels, andbackside surfaces of seats), televisions, monitors, household appliancesor architectural structures may be subjected to accidental pushing,pressing, or rubbing by users, and may be subjected to temperatureextremes, e.g. in the summer or in the winter in certain climates.

Further, sunlight can shine on surface display units (especially in anautomobile and buildings) from time to time, reducing the clarity of thesignal or message, or level of enjoyment of the viewer from time totime. In addition, surface texture providing a luxurious atmosphere maybe desirable for surface display units incorporated into vehicles suchas automobiles, boats, and airplanes (e.g., glazing such as windshields,windows or sidelites, mirrors, pillars, side panels of a door,headrests, dashboards, consoles, or seats of the vehicle, or anyportions thereof), architectural fixtures or structures (e.g., windows,internal or external walls of building, and flooring), appliances (e.g.,a refrigerator, an oven, a stove, a washer, a dryer, or anotherappliance), consumer electronics (e.g., televisions, laptops, computermonitors, and handheld electronics such as mobile phones, tablets, andmusic players), furniture, information kiosks, retail kiosks, and thelike.

SUMMARY

According to various aspects of the disclosure, surface display unitsincorporating opaque screens are provided. As used herein, the term“opaque” refers to the opacity perceived by a user or viewer of thesurface display unit when the surface display unit is in a powered “off”state or opaque but powered “on” state. Opaque may include atransmittance of 0% to about 25% within the wavelength range from 400 nmto 800 nm. In at least various embodiments, the opaque screens mayprovide one or more property chosen from optical enhancement, decorativetexture, and/or mechanical support or protection to the surface displayunit. The opaque screen can be proximate to or disposed on the frontside (i.e., the side facing the viewer) of an image source or panel thatprovides an optical image (and thus, the optical image is visiblethrough the opaque screen). In such embodiments, the opaque screengenerally hides the image panel while the surface display unit is not inuse. When the image panel is activated to provide an optical image, theopaque screen may provide some degree of transparency such that a viewercan observe the optical image with sufficient clarity.

In one or more embodiments, the opaque screen may function as a screenfor an image source, such as a projector, that provides an optical imageon the opaque screen from the front side (i.e., the side of the viewer).In some embodiments, the optical image is visible either through theopaque screen (in the case where the opaque screen is between the viewerand the image source) or on the opaque screen (in the case where theviewer and the image source are on the same side as one another).

According to an aspect of the present disclosure, a surface display unitis provided, which comprises an image panel configured to provide anoptical image on a front surface thereof; and an opaque screen disposedover the front surface of the image panel. The opaque screen comprisesan opaque matrix material layer that attenuates light impingingthereupon from a front side of the opaque matrix material layer andtransmitting light from the image panel. According to an aspect of thepresent disclosure, a surface display unit is provided, which comprisesan opaque screen including a front surface, and an image source disposedon the same side as a viewer (with respect to the opaque screen), theimage source configured to provide an optical image on the frontsurface. The opaque screen comprises an opaque matrix material layerthat attenuates light impinging thereupon from a front side of theopaque matrix material layer and reflecting light from the image source.

In one or more embodiments, the surface display units incorporated intovehicles such as automobiles, boats, and airplanes (e.g., in glazingsuch as windshields, windows or sidelites, mirrors, pillars, side panelsof a door, headrests, dashboards, consoles, or seats of the vehicle, orany portions thereof), architectural fixtures or structures (e.g.,internal or external walls of building, and flooring), appliances (e.g.,a refrigerator, an oven, a stove, a washer, a dryer, or anotherappliance), consumer electronics (e.g., televisions, laptops, computermonitors, and handheld electronics such as mobile phones, tablets, andmusic players), furniture, information kiosks, retail kiosks, and thelike. In one or more embodiments, an automobile comprises a surface andthe surface display unit is disposed on at least a portion of thesurface. The surface may include any one of a glazing (e.g., such aswindshields, windows or sidelites), a mirror, a pillar, a door panel, anarmrest, a headrest, a dashboard, a console, or a seat of the vehicle).

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic vertical cross-sectional view of an exemplarysurface display unit incorporating an opaque screen that provides somedegree of optical opacity and an image panel that provides an opticalimage according to an embodiment of the present disclosure.

FIG. 2 is a schematic perspective view of the inside of an automobilehaving a dashboard with an exemplary surface display unit incorporatedtherein according to an embodiment of the present disclosure.

FIG. 3 is a graph illustrating changes in transmission coefficient forembodiments in which the optical properties of the opaque matrixmaterial layer changes upon application of a suitable external stimulus.

DETAILED DESCRIPTION

As discussed above, the present disclosure is directed to surfacedisplay units comprising an opaque screen, the various aspects of whichare described herein in detail.

The drawings are not drawn to scale. Multiple instances of an elementmay be duplicated where a single instance of the element is illustrated,unless absence of duplication of elements is expressly described orclearly indicated otherwise. Ordinals such as “first,” “second,” and“third” are employed merely to identify similar elements, and differentordinals may be employed across the specification and the claims of theinstant disclosure without limitation. As used herein, a first elementlocated “on” a second element can be located on an exterior side of asurface of the second element or on an interior side of the secondelement. As used herein, a first element is located “directly on” asecond element if there exists a physical contact between a surface ofthe first element and a surface of the second element.

As used herein, a “layer” refers to a material portion including aregion having a substantially uniform thickness. A layer may extend overthe entirety of an underlying or overlying structure, or may have anextent less than the extent of an underlying or overlying structure.Further, a layer may be a region of a homogeneous or inhomogeneouscontiguous structure that has a thickness less than the thickness of thecontiguous structure. For example, a layer may be located between anypair of horizontal planes between, or at, a top surface and a bottomsurface of the contiguous structure. A layer may extend horizontally,vertically, and/or along a tapered surface. A substrate may be a layer,may include one or more layers therein, or may have one or more layerthereupon, thereabove, and/or therebelow.

Referring to FIG. 1, an exemplary surface display unit 100 isillustrated, which incorporates an opaque screen 180 that provides somedegree of optical opacity, and an image panel 110 that provides anoptical image. The image panel 110 may comprise a micro-LED, an OLED, aLCD, a plasma cell, an electroluminescent (EL) cell array, or anothersuitable element configured to emit radiation).

As used herein, an “optical image” can be any image that is generated bylight (for example generated by a pattern of light). The light can bemonochromatic, polychromatic, or can be a continuous spectrum ofwavelengths. As used herein, an “image” can be any physical pattern, andincludes pictures, letters, numbers, or any other pattern includingcontrast in color and/or brightness. The opaque screen 180 may, in atleast some embodiments, provides protection for the image panel 110 fromphysical damage by being disposed in front of the image panel. Theexemplary surface display unit 100 can include a stack of layers, whichcan be, from back to front in one exemplary and non-limiting embodiment,the image panel 110, a thin adhesive layer 120, an opaque matrixmaterial layer 130, an optional anti-scratch layer 140, an optionalantireflection layer 150, and an optional antiglare layer 160. Greateror fewer numbers of layers, and alternate configurations of layers, maybe chosen in various embodiments.

The exemplary surface display unit 100 of FIG. 1 may be useful in avariety of applications. For example, the exemplary surface display unitcan be affixed in, on, or to any surface, which can be a fixed structuresuch as a wall of a building, or a surface of a household appliance(such as an oven or stove). Alternatively, the exemplary surface displayunit 100 of FIG. 1 can be affixed in, on, or to a surface that is acomponent of a moving object, such as an automobile dashboard orconsole, an inner sidewall of a door, or a backside surface of a seatwithin an automobile, or a door of a refrigerator. In some instances,the surface display unit 100 may be utilized in vehicles such asautomobiles, boats, and airplanes (e.g., glazing such as windshields,windows or sidelites, mirrors, pillars, side panels of a door,headrests, dashboards, consoles, or seats of the vehicle, or anyportions thereof), architectural fixtures or structures (e.g., internalor external walls of building, and flooring), appliances (e.g., arefrigerator, an oven, a stove, a washer, a dryer, or anotherappliance), consumer electronics (e.g., televisions, laptops, computermonitors, and handheld electronics such as mobile phones, tablets, andmusic players), furniture, information kiosks, retail kiosks, and thelike. FIG. 2 illustrates an exemplary installation of the surfacedisplay unit 100 within a dashboard of an automobile. In one or moreembodiments, an automobile comprises a surface and the surface displayunit is disposed on at least a portion of the surface. The surface mayinclude any one of a glazing (e.g., such as windshields, windows orsidelites), a mirror, a pillar, a door panel, an armrest, a headrest, adashboard, a console, or a seat of the vehicle).

Referring back to FIG. 1, the opaque screen 180 may appear generallydark, or may appear to have a preselected color when the image panel 110is not activated, i.e. does not generate an optical image. However, theopacity of the opaque screen 180, the composition and/or thickness ofthe adhesive layer 120, if present, and/or the brightness of the opticalimage may be selected such that the optical image generated on the imagepanel 110 can be transmitted through the opaque screen 180 withoutsignificant degradation of clarity of the optical image so that it maybe visible to a user. In other words, the opaque screen 180 is a“see-through” screen, i.e. has some degree of transparency ortranslucency, for the purpose of viewing the optical image generated onthe image panel 110.

The opaque screen 180 can include an opaque matrix material layer 130,which includes an optically opaque material having non-zero transmissioncoefficient to allow transmission of the optical image formed on theimage panel 110. The opaque matrix material layer 130 can comprise oneor more various types of materials to provide the desiredfunctionalities. In one embodiment, the opaque matrix material layer130, which may comprise one or more layers, can be thick enough toprovide sufficient mechanical strength to the opaque screen 180, and/orto prevent breakage or fracture of the opaque screen 180. The thicknessof the opaque screen 180 can be selected to minimize the volume ofmaterial layers present proximate to, or disposed on, the image panel110. In one embodiment, the total thickness of material layers of theopaque screen 180 proximate to, or disposed on, the image panel 110 canrange from about 0.3 mm to about 30 mm, from about 0.5 mm to about 20mm, from about 0.7 mm to about 10 mm, or from about 1 mm to about 30 mm.In some embodiments, the total thickness of material layers of theopaque screen 180 can be in any range from about 1 mm to about 3 mm,from about 2 mm to about 6 mm, from about 3 mm to about 9 mm, from about5 mm to about 15 mm, from about 10 mm to about 30 mm, or from any firstintermediate thickness to any second intermediate thickness greater thanthe first intermediate thickness.

In one or more embodiments, the opaque screen 180 can provide ascattering surface on which a projected display may be visible. Forexample, as shown in FIG. 1, an image source 200 may be disposed on thesame side as a viewer and the image may be projected from image source200 onto the front surface of the opaque screen 180. In someembodiments, an image or images from the image panel 110 and from theimage source 200 may be simultaneously visible on the front surface ofthe opaque screen 180. In some embodiments, an image or images from theimage panel 110 or from the image source 200 may be visible on the frontsurface of the opaque screen 180 in a non-simultaneous fashion.

In various exemplary and non-limiting embodiments, the opaque matrixmaterial layer 130 may comprise one or more layers comprising apolymeric material, glass material (e.g., soda lime glass, alkalialuminosilicate glass, alkali containing borosilicate glass and/oralkali aluminoborosilicate glass), poly-ceramic material, orglass-ceramic material, for example. The material may, in variousembodiments, be provided as a single sheet or as part of a laminate orstacked structure. In cases where a laminate structure is employed forthe opaque matrix material layer 130, the layers of the laminate may bechosen from the same or different materials.

In some examples, the thickness of one or more layers of the opaquematrix material layer 130 may be significantly reduced when provided aspart of a laminate (e.g., less than about 1 mm), without the need foradditional polishing or grinding steps often utilized to reducedthickness. According to various exemplary embodiments, the thickness ofthe individual layers and/or the total thickness of material layers ofthe opaque matrix material layer 130 can range from about 0.05 mm toabout 30 mm, and can be in any range from about 0.1 mm to about 3 mm,from about 0.2 mm to about 6 mm, from about 3 mm to about 9 mm, fromabout 5 mm to about 15 mm, from about 10 mm to about 30 mm, or from anyfirst intermediate thickness to any second intermediate thicknessgreater than the first intermediate thickness.

The glass materials used in embodiments of the opaque matrix materialsmay be provided using a variety of different processes. For instance,where the glass material may be formed using known forming methodsinclude float glass processes and down-draw processes such as fusiondraw and slot draw.

A glass material prepared by a float glass process may be characterizedby smooth surfaces and uniform thickness is made by floating moltenglass on a bed of molten metal, typically tin. In an example process,molten glass that is fed onto the surface of the molten tin bed forms afloating glass ribbon. As the glass ribbon flows along the tin bath, thetemperature is gradually decreased until the glass ribbon solidifiesinto a solid glass material that can be lifted from the tin ontorollers. Once off the bath, the glass material can be cooled further andannealed to reduce internal stress.

Down-draw processes produce glass materials having a uniform thicknessthat possess relatively pristine surfaces. Because the average flexuralstrength of glass materials is controlled by the amount and size ofsurface flaws, a pristine surface that has had minimal contact has ahigher initial strength. When this high strength glass material is thenfurther strengthened (e.g., chemically), the resultant strength can behigher than that of a glass material with a surface that has been lappedand polished. Down-drawn glass materials may be drawn to a thickness ofless than about 2 mm. In addition, down drawn glass materials have avery flat, smooth surface that can be used in its final applicationwithout costly grinding and polishing.

The glass material may be formed using a fusion draw process, forexample, which uses a drawing tank that has a channel for acceptingmolten glass raw material. The channel has weirs that are open at thetop along the length of the channel on both sides of the channel. Whenthe channel fills with molten material, the molten glass overflows theweirs. Due to gravity, the molten glass flows down the outside surfacesof the drawing tank as two flowing glass films. These outside surfacesof the drawing tank extend down and inwardly so that they join at anedge below the drawing tank. The two flowing glass films join at thisedge to fuse and form a single flowing glass material. The fusion drawmethod offers the advantage that, because the two glass films flowingover the channel fuse together, neither of the outside surfaces of theresulting glass material comes in contact with any part of theapparatus. Thus, the surface properties of the fusion drawn glassmaterial are not affected by such contact.

The slot draw process is distinct from the fusion draw method. In slowdraw processes, the molten raw material glass is provided to a drawingtank. The bottom of the drawing tank has an open slot with a nozzle thatextends the length of the slot. The molten glass flows through theslot/nozzle and is drawn downward as a continuous material and into anannealing region.

In some embodiments, the compositions used for the glass material may bebatched with 0 mol % to about 2 mol. % of at least one fining agentselected from a group that includes Na₂SO₄, NaCl, NaF, NaBr, K₂SO₄, KCl,KF, KBr, and SnO₂.

Once formed, a glass material may be strengthened to form a strengthenedglass material. It should be noted that glass-ceramics described hereinmay also be strengthened in the same manner as glass materials. As usedherein, the term “strengthened material” may refer to a glass materialor a glass-ceramic material that has been chemically strengthened, forexample through ion-exchange of larger ions for smaller ions in thesurface of the glass or glass-ceramic material. However, otherstrengthening methods known in the art, such as thermal tempering, maybe utilized to form strengthened glass materials and/or glass-ceramicmaterials. In some embodiments, the materials may be strengthened usinga combination of chemical strengthening processes and thermallystrengthening processes.

The strengthened materials described herein may be chemicallystrengthened by an ion exchange process. In the ion-exchange process,typically by immersion of a glass or glass-ceramic material into amolten salt bath for a predetermined period of time, ions at or near thesurface(s) of the glass or glass-ceramic material are exchanged forlarger metal ions from the salt bath. In one embodiment, the temperatureof the molten salt bath is in the range from about 400° C. to about 430°C. and the predetermined time period is about four to about twenty-fourhours; however the temperature and duration of immersion may varyaccording to the composition of the material and the desired strengthattributes. The incorporation of the larger ions into the glass orglass-ceramic material strengthens the material by creating acompressive stress in a near surface region or in regions at andadjacent to the surface(s) of the material. A corresponding tensilestress is induced within a central region or regions at a distance fromthe surface(s) of the material to balance the compressive stress. Glassor glass-ceramic materials utilizing this strengthening process may bedescribed more specifically as chemically-strengthened or ion-exchangedglass or glass-ceramic materials.

In one example, sodium ions in a strengthened glass or glass-ceramicmaterial are replaced by potassium ions from the molten bath, such as apotassium nitrate salt bath, though other alkali metal ions havinglarger atomic radii, such as rubidium or cesium, can replace smalleralkali metal ions in the glass. According to particular embodiments,smaller alkali metal ions in the glass or glass-ceramic can be replacedby Ag+ ions. Similarly, other alkali metal salts such as, but notlimited to, sulfates, phosphates, halides, and the like may be used inthe ion exchange process.

The replacement of smaller ions by larger ions at a temperature belowthat at which the glass network can relax produces a distribution ofions across the surface(s) of the strengthened material that results ina stress profile. The larger volume of the incoming ion produces acompressive stress (CS) on the surface and tension (central tension, orCT) in the center of the strengthened material. The compressive stressis related to the central tension by the following relationship:

${CS} = {{CT}( \frac{t - {2{DOL}}}{DOL} )}$

where t is the total thickness of the strengthened glass orglass-ceramic material and compressive depth of layer (DOL) is the depthof exchange. Depth of exchange may be described as the depth within thestrengthened glass or glass-ceramic material (i.e., the distance from asurface of the glass material to a central region of the glass orglass-ceramic material), at which ion exchange facilitated by the ionexchange process takes place.

In one embodiment, a strengthened glass or glass-ceramic material canhave a surface compressive stress of 300 MPa or greater, e.g., 400 MPaor greater, 450 MPa or greater, 500 MPa or greater, 550 MPa or greater,600 MPa or greater, 650 MPa or greater, 700 MPa or greater, 750 MPa orgreater or 800 MPa or greater. The strengthened glass or glass-ceramicmaterial may have a compressive depth of layer 15 μm or greater, 20 μmor greater (e.g., 25 μm, 30 μm, 35 μm, 40 μm, 45 μm, 50 μm or greater)and/or a central tension of 10 MPa or greater, 20 MPa or greater, 30 MPaor greater, 40 MPa or greater (e.g., 42 MPa, 45 MPa, or 50 MPa orgreater) but less than 100 MPa (e.g., 95, 90, 85, 80, 75, 70, 65, 60, 55MPa or less). In one or more specific embodiments, the strengthenedglass or glass-ceramic material has one or more of the following: asurface compressive stress greater than 500 MPa, a depth of compressivelayer greater than 15 μm, and a central tension greater than 18 MPa.

Example glasses that may be used in the glass material may includealkali aluminosilicate glass compositions or alkali aluminoborosilicateglass compositions, though other glass compositions are contemplated.Such glass compositions may be characterized as ion exchangeable. Asused herein, “ion exchangeable” means that a material comprising thecomposition is capable of exchanging cations located at or near thesurface of the material with cations of the same valence that are eitherlarger or smaller in size. One example glass composition comprises SiO₂,B₂O₃ and Na₂O, where (Sift+B₂O₃)≥66 mol. %, and Na₂O≥9 mol. %. In anembodiment, the glass composition includes at least 6 wt. % aluminumoxide. In a further embodiment, the material includes a glasscomposition with one or more alkaline earth oxides, such that a contentof alkaline earth oxides is at least 5 wt. %. Suitable glasscompositions, in some embodiments, further comprise at least one of K₂O,MgO, and CaO. In a particular embodiment, the glass compositions used inthe material can comprise 61-75 mol. % SiO₂; 7-15 mol. % Al₂O₃; 0-12mol. % B₂O₃; 9-21 mol. % Na₂O; 0-4 mol. % K₂O; 0-7 mol. % MgO; and 0-3mol. % CaO.

A further example glass composition suitable for the material comprises:60-70 mol. % Sift; 6-14 mol. % Al₂O₃; 0-15 mol. % B₂O₃; 0-15 mol. %Li₂O; 0-20 mol. % Na₂O; 0-10 mol. % K₂O; 0-8 mol. % MgO; 0-10 mol. %CaO; 0-5 mol. % ZrO₂; 0-1 mol. % SnO₂; 0-1 mol. % CeO₂; less than 50 ppmAs₂O₃; and less than 50 ppm Sb₂O₃; where 12 mol. % (Li₂O+Na₂O+K₂O)≤20mol. % and 0 mol. %≤(MgO+CaO)≤10 mol. %.

A still further example glass composition suitable for the glassmaterial comprises: 63.5-66.5 mol. % SiO₂; 8-12 mol. % Al₂O₃; 0-3 mol. %B₂O₃; 0-5 mol. % Li₂O; 8-18 mol. % Na₂O; 0-5 mol. % K₂O; 1-7 mol. % MgO;0-2.5 mol. % CaO; 0-3 mol. % ZrO₂; 0.05-0.25 mol. % SnO₂; 0.05-0.5 mol.% CeO₂; less than 50 ppm As₂O₃; and less than 50 ppm Sb₂O₃; where 14mol. %≤(Li₂O+Na₂O+K₂O)≤18 mol. % and 2 mol. %≤(MgO+CaO)≤7 mol. %.

In a particular embodiment, an alkali aluminosilicate glass compositionsuitable for the glass material comprises alumina, at least one alkalimetal and, in some embodiments, greater than 50 mol. % SiO₂, in otherembodiments at least 58 mol. % SiO₂, and in still other embodiments atleast 60 mol. % SiO₂, wherein the ratio ((Al₂O₃+B₂O₃)/Σmodifiers)>1,where in the ratio the components are expressed in mol. % and themodifiers are alkali metal oxides. This glass composition, in particularembodiments, comprises: 58-72 mol. % SiO₂; 9-17 mol. % Al₂O₃; 2-12 mol.% B₂O₃; 8-16 mol. % Na₂O; and 0-4 mol. % K₂O, wherein the ratio((Al₂O₃+B₂O₃)/Σmodifiers)>1.

In still another embodiment, the substrate may include an alkalialuminosilicate glass composition comprising: 64-68 mol. % SiO₂; 12-16mol. % Na₂O; 8-12 mol. % Al₂O₃; 0-3 mol. % B₂O₃; 2-5 mol. % K₂O; 4-6mol. % MgO; and 0-5 mol. % CaO, wherein: 66 mol. %≤SiO₂+B₂O₃+CaO≤69 mol.%; Na₂O+K₂O+B₂O₃+MgO+CaO+SrO>10 mol. %; 5 mol. %≤MgO+CaO+SrO≤8 mol. %;(Na₂O+B₂O₃)—Al₂O₃≤2 mol. %; 2 mol. %≤Na₂O—Al₂O₃≤6 mol. %; and 4 mol. %(Na₂O+K₂O)—Al₂O₃≤10 mol. %.

In an alternative embodiment, the glass material may comprise an alkalialuminosilicate glass composition comprising: 2 mol % or more of Al₂O₃and/or ZrO₂, or 4 mol % or more of Al₂O₃ and/or ZrO₂.

In some instances, the opaque matrix material may incorporate aglass-ceramic that may be fusion-formed or formed by other known methodssuch as rolling, thin-rolling, slot draw or float. In some embodiments,a glass-ceramic layer provided as part of a laminate may be fusionformed.

Exemplary glass-ceramics useful according to various embodimentsdescribed herein may be characterized by the processes by which they canbe formed. Such glass-ceramics may be formed by float processes, fusionprocesses, slot draw process, thin rolling processes, or a combinationthereof. Some glass-ceramics tend to have liquidus viscosities thatpreclude the use of high throughput forming methods such as float, slotdraw, or fusion draw. For example, known glass-ceramics are formed fromprecursor glasses having liquidus viscosities of about 10 kP, which arenot suitable for fusion draw, where liquidus viscosities of above 100 kPor above 200 kP are generally required. Glass-ceramics formed by the lowthroughput forming methods (e.g., thin rolling) may exhibit enhancedopacity, various degrees of translucency, and/or surface luster.Glass-ceramics formed by high throughout methods (e.g., float, slotdraw, or fusion draw) can achieve very thin layers. Glass-ceramicsformed by fusion draw methods may achieve pristine surfaces and thinness(e.g., about 2 mm or less). Examples of suitable glass-ceramics mayinclude Li₂O—Al₂O₃—SiO₂ system (i.e. LAS-System) glass-ceramics,MgO—Al₂O₃—SiO₂ system (i.e. MAS-System) glass-ceramics, glass-ceramicsincluding crystalline phases of any one or more of mullite, spinel,α-quartz, β-quartz solid solution, petalite, lithium dissilicate,β-spodumene, nepheline, and alumina, and combinations thereof.

In one embodiment, the opaque matrix material layer 130 can include acombination of a glass layer and a diffusion material layer (e.g., adiffuser film or a light-scattering film). According to variousexemplary embodiments, the diffusion layer may comprise a polymericmaterial. The diffuser material layer may be a single layer or a stackof multiple layers provided that there is at least one material layerthat is engineered to provide optical scattering. In an illustrativeexample, optical scattering within a diffusion material layer may beprovided by a light diffuser film made of polymers.

The glass layer may be replaced with any other optically transparentmaterial layer in various exemplary embodiments such as embodimentswhere durability is not an issue or in non-window applications (as inthe case of a surface display unit located on an exterior door panel ofan automobile, door of an appliance, walls, countertops, monitors andthe like).

In one embodiment, high ambient contrast may be provided by minimizingthe effect of ambient radiation impinging on the opaque matrix materiallayer 130, while minimizing the change in the transmission coefficientof the light from the image panel 110.

In one embodiment, the opaque matrix material layer 130 can include aglass core with at least one optically opaque cladding thereupon. The atleast one optically opaque cladding can include a ceramic material orglass-ceramic material having optical opacity. The transmissioncoefficient of each optically opaque cladding can be in a range from0.01 to 0.5. In one embodiment, the transmission coefficient of eachoptically opaque cladding can be in a range from 0.01 to 0.05, from 0.02to 0.1, from 0.03 to 0.14, from 0.05 to 0.15, from 0.1 to 0.5, or anyintermediate range between any of the previous ranges. In oneembodiment, a pair of optically opaque claddings can be provided suchthat both sides of the glass core are contacted by an optically opaquecladding. Optionally, one or both of the optically opaque claddings canbe machined with laser ablation, or with a liquid phase etchant or a gasphase etchant to provide a decorative ceramic laminated glass.

In one embodiment, the opaque matrix material layer 130 can include adye-sensitized material layer. In this case, the opaque matrix materiallayer 130 can be a dye-sensitized screen (i.e., a dye-doped screen) thatchanges color upon irradiation of an activating radiation thereupon. Inone embodiment, the activating radiation may be provided by a lightsource (not shown) provided on either side, or on both sides, of theopaque matrix material layer 130. In another embodiment, the activatingradiation may be provided by a light source provided within the imagepanel 110. In this case, the activating radiation may be provided by aset of at least one dedicated light source embedded within the imagepanel 110 and separate from the light sources employed to form theoptical image, or may be provided by a subset of the light sources thatcan be employed to form the optical image. In one embodiment, theactivating radiation may be ultraviolet light or visible light. Theactivating radiation may be provided by one or more light emittingdiodes. In one embodiment, only one type of activating radiation sourcemay be provided. In another embodiment, multiple dye materials that areactivated to emit lights of different wavelengths and/or activated byradiation of different wavelengths may be embedded within the opaquematrix material layer 130. In this case, multiple types of activatingradiation having different wavelengths may be employed to cause theopaque matrix material layer 130 to display different colors dependingon the wavelength of the activating radiation.

In one embodiment, the opaque matrix material layer 130 can include adye-doped liquid crystal that incorporates two or more materials thatinteract with each other or with one another to generate opticaleffects. In one embodiment, the dye-doped liquid crystal can be employedto reduce transmission of light, thereby providing an opaque materialportion that provides a low level of optical transmission from the imagepanel 110 to the viewer.

In one embodiment, the opaque matrix material layer 130 can include amaterial having one or more peaks in the transmission coefficient as afunction of wavelength within the range from 400 nm to 800 nm. In oneembodiment, the peaks in the transmission coefficient can correspond tothe wavelengths of illumination radiation of the optical image formed atthe image panel 110. For example, if the optical image is formed byactive matrix light emitting diodes embedded within the image panel 110,the wavelengths of the peaks in the transmission coefficient of thematerial of the opaque matrix material layer 130 can roughly correspondto the peak wavelengths of the light emitting diodes in the image panel110. For example, if the image panel 110 employs red, green, and bluelight emitting diodes, the peaks in the transmission coefficient of thematerial of the opaque matrix material layer 130 can coincide with thewavelengths at which the intensity of each radiation from the red,green, and blue light emitting diodes becomes a maximum. The generallylight-absorbing property of the opaque matrix material layer 130 candecrease scattering of ambient light, thereby enhancing the contrast ofthe optical image displayed on the image panel 110.

In one embodiment, the opaque matrix material layer 130 can include anycombination of previously described material layers to provide multiplefunctionalities. In this case, the transmissive coefficient of theopaque matrix material layer 130 can be the product of the transmissivecoefficients of the individual material layers employed for the opaquematrix material layer 130.

The opaque screen 180 can include at least one additional layer toprovide desired optical properties to a viewer. For example, theprotective optical screen may optionally include at least one opticalmaterial layer chosen to reduce or prevent hazing (caused by lateralscattering of light), halo effects, and/or ghosting (manifestation ofmultiple images due to multiple reflections). It may, in variousembodiments, be desirable to choose a combination of materials toachieve such effects.

In one embodiment, the opaque screen 180 may include optical featuresconfigured to channel or guide light from the front surface of the imagepanel 110.

In other embodiments, the opaque screen 180 may be substantially free ofoptical defects, such as distortions (e.g., those created by draw linesfrom glass forming) and flaws that could diminish the quality of thedisplay. Such defects are often found in typical thick glass, such asthick soda lime glass, which is formed by float methods. In other words,the opaque screen 180 may exhibit high end display quality attributestypically found in high definition televisions and other electronicdevices. In other embodiments, the opaque screen 180 provides atouch-ready surface that enables touch functionality.

In other embodiments, the opaque screen 180 may be suitable for surfacetreatments including coatings, to enhance the display performance. Theopaque screen 180 can optionally include an antiglare layer 160, anantireflection layer 150, an anti-scratch layer 140, or any combinationthereof. In case more than one of the antiglare layer 160, theantireflection layer 150, and the anti-scratch layer 140 is provide, theorder of the various layers may be permutated as needed. For example, anantiglare layer can be provided in surface display units in order toprovide a low level of gloss on the front side of the surface displayunits. In one embodiment, the outermost layer may be an antiglare layer160.

The antiglare layer 160, if present, provides anti-glare finish. Theantiglare layer 160 may be a contiguous layer or may include particlesadhering to an underlying layer. The anti-glare finish is an optionalfinish that can be applied to the surface of the surface display unit100 that faces the viewer. The anti-glare finish can be provided, forexample, by texturing the surface to provide macro features, and/ordisposing macro-sized features (e.g., particles) on the surface of theglass. The anti-glare finish provides a smooth finish for touchfunction/“swiping” due to reduced surface area on which the user'sfinger glides. Such smooth finish can alternatively be provided byapplying various coatings including “easy to clean” (orhydrophobic/oleophobic) coatings that are currently found on many mobilephones.

In one embodiment, the opaque screen 180 may include a polarizationfilter to reduce scattering of ambient light without hinderingtransmission of the light therethrough from the image panel 110.

In one embodiment, an adhesive layer 120 may be employed between theopaque screen 180 and the image panel 110. The adhesive layer 120 mayhave a thickness in a range from 0.5 micron to 100 microns, althoughlesser and greater thicknesses can also be employed. The material of thethin adhesive layer 120 may be selected to minimize scattering of lightat the thin adhesive layer.

Optionally, a backer material layer (a light blocking material layer)may be employed to shield the LED's, which is disposed behind thebacker. In some cases, the backer material layer can be a stencil thatshows some functional indicators. If present, the backer material layermay be disposed between the opaque matrix material layer 130 and theimage panel 110.

In one embodiment, the opaque matrix material layer 130 may be capableof being switched between two states. The opaque matrix material layer130 may provide a first level of light transmission in a first state, oran “on” state, and provide a second level of light transmission in asecond state, or an “off” state. The transmission coefficient of theopaque matrix material layer 130 as a function of wavelength is thusdependent on the state of the opaque matrix material layer 130.

FIG. 3 illustrates an exemplary set of transmission coefficient curvesthat can be provided by a bi-state or multi-state opaque matrix materiallayer 130. The opaque matrix material layer 130 can have a firsttransmission coefficient curve 310, or an “on-state transmissioncoefficient curve,” as a function of wavelength when the opaque matrixmaterial layer 130 is in the on state, and can have a secondtransmission coefficient curve 320, or an “off-state transmissioncoefficient curve,” as a function of wavelength when the opaque matrixmaterial layer 130 is in the off state. The ratio of the transmissioncoefficient for the off-state to the transmission coefficient for theon-state may be in a range from 0.001 to 0.5 within the wavelength rangefrom 400 nm to 800 nm. The ratio of the transmission coefficient for theoff-state to the transmission coefficient for the on-state may be,within the wavelength range from 400 nm to 800 nm, in any one of theranges from 0.001 to 0.05, from 0.002 to 0.01, from 0.005 to 0.025, from0.01 to 0.05, from 0.02 to 0.1, from 0.05 to 0.025, and from 0.1 to 0.5,or any of the ranges in between. In some examples, the display surfaceunit is at least partially transparent to visible light. Ambient light(e.g., sunlight) may make the display image difficult or impossible tosee when projected or emitted on such a display surface. In someexamples, the display surface, or portion thereof on which the displayimage is projected or emitted, can include a darkening material such as,for example, an inorganic or organic photochromic or electrochromicmaterial, a suspended particle device and/or a polymer dispersed liquidcrystal. Thus, the transparency of the surface can be adjusted toincrease the contrast of the display image provided at the displaysurface. For example, the transparency of the display surface can bereduced in bright sunlight by darkening the display surface to increasethe contrast of the display image. The adjustment can be controlledautomatically (e.g., in response to exposure of the display surface to aparticular wavelength of light, such as ultraviolet light, or inresponse to a signal generated by a light detector, such as a photoeye)or manually (e.g., by a viewer).

In one or more embodiments, the different transmission coefficients indifferent states of the opaque matrix material layer 130 can be providedby any known method, for example by choosing an electrochromaticmaterial or a photochromatic material. In one embodiment, the opaquematrix material layer 130 can include electrochromatic material layer.In this case, the opaque matrix material layer 130 can include anelectrochromatic material that becomes more opaque upon application of avoltage bias.

In one embodiment, the opaque matrix material layer 130 can include aphotochromatic material layer. The photochromatic material changestransmission coefficient when activated by an activating radiation. Forexample, the photochromatic material can include a matrix of polyvinylbutyral (PVB) embedding quantum dots that are activated by theactivating radiation, and render the matrix semi-opaque or opaque.

Referring back to FIG. 1, the image panel 110 can include an imagedisplay device, i.e., a device that displays an optical image. In oneembodiment, the image panel 110 can include a display unit thatgenerates an image employing a single illumination source such as a deadfront display device. Alternatively or additionally, the image panel 110can include a pixilated display device such as a liquid crystal displaydevice and/or a light emitting display device.

In one embodiment, the image panel 110 may include micro light emittingdiodes (micro-LED's). A plurality of micro-LED's can be provided in anarray pattern so that each micro-LED constitutes a sub-pixel of apixilated display device. A layer of a semiconductor material (such assilicon) controls the amount of light each micro-LED emits. Thus, eachmicro-LED itself serves as the component that forms an image. In oneembodiment, the mciro-LED's can be provided as a pixilated displaydevice including a set of multiple micro-LED's having different colorswithin each pixel.

In one embodiment, the image panel 110 can have multiple brightnesssettings to provide different amount of illumination during the day timeand the night time. In one embodiment, the brightness of the image panel110 may be automatically adjusted to provide a suitable level ofillumination from the display image to the viewer. In one embodiment, anambient light sensor located in proximity to the opaque screen 180 canprovide the necessary input to determine the optimal brightness level ofthe image displayed on the image panel 110.

In one embodiment, the image panel 110 can have a color weightedbrightness adjustment system to compensate for a non-uniformtransmission coefficient curve within the visible wavelength range. Forexample, if the opaque matrix material layer 130 provides a highertransmission coefficient for red light than for blue light, the colorweighted brightness adjustment system of the image panel 110 canincrease the brightness of the illumination for the blue light and/ordecrease the brightness of the illumination for the red light so thatthe viewer perceives an optical image having the same color intensitydistribution as would be present within an original optical image, i.e.,an optical image without any optical filter thereupon.

In one embodiment, the viewing angle of the surface display unit can beselected to suit the purpose of the displayed images. If the surfacedisplay unit primarily displays images intended for entertainment, theviewing angle for the surface display unit can be adjusted to provideviewing capability to all potential viewers in proximity to the surfacedisplay unit. For example, if the surface display unit is employed in anautomobile, the viewing angle for the surface display unit can beselected to provide viewing capability to all passengers in theautomobile. Alternatively, if the surface display unit primarilydisplays images (such as control signals) that are useful only to aperson at a particular position (such as the driver of an automobile),the viewing angle can be adjusted to provide the image most clearly tothe person who needs to view the image.

In one embodiment, the opaque screen 180 can include optical features toprovide a narrow viewing angle so that only a viewer at a predeterminedangle and/or position can view the optical image through the opaquescreen 180. Such optical features include, but are not limited to,gratings and arrays of reflective surfaces.

Without wishing to be limited, the following examples are provided forillustrative purposes only.

In a first illustrative example, the opaque matrix material layer 130can include a laminate including at least a glass layer and a polymerlayer (which functions as a diffusion material layer). The glass layercan be a 0.65 mm thick layer of aluminosilicate glass having thefollowing composition: 70 mol % SiO₂, 8.5 mol % Al₂O₃, 14 mol % Na₂O,1.2 mol % K₂O, 6.5 mol % MgO, 0.5 mol % CaO, and 0.2 mol % SnO₂. Thealuminosilicate glass can be chemically strengthened by immersing in amolten salt bath to generate a surface compressive stress extending to adepth within in the glass.

The front surface of the aluminosilicate glass (i.e., the surface facingthe viewer) can have anti-glare finish of 14% haze, which providestranslucent appearance. At this level, one could see an analog clock(non-luminescent type) behind such a surface, but would not be able totell what time it is based on the display on the clock.

A polymer layer forming a diffusion surface is employed as a diffusionmaterial layer. The polymer layer can be present on the front side ofthe aluminosilicate glass or on the back side of the aluminosilicateglass. The polymer layer can be at least one polyethylene terephthalate(PET) layer. The polymer layer can have a white appearance, and can belaminated to the layer of the aluminosilicate glass as a cladding layer.The polymer layer tested employed a polymer material originally providedby Prodisplay™ and custom-tailored to reduce halo effects.

The thin adhesive layer 120 can include an acrylic adhesive, which maybe omitted if the image panel and the opaque matrix material layer 130can be spatially fixed with respect to each other. Without employing athin adhesive layer 120, the polymer layer may be placed between thealuminosilicate glass and the image panel 110. In this case, the polymerlayer may be laminated between polyvinyl butyral (PVB) layers or betweenthermoplastic polyurethane (TPU) layers (as in a windshield laminate).The image panel 110 may employ light emitting diodes (LED's).

In a second illustrative example, the opaque matrix material layer 130can include the same aluminosilicate glass as in the first illustrativeexample. The aluminosilicate glass can be chemically strengthened byimmersing in a molten salt bath to generate a surface compressive stressextending to a depth within in the glass.

As in the first illustrative example, the front surface of thealuminosilicate glass can have anti-glare finish of 14% haze, whichprovides translucent appearance.

A polymer layer forming a diffusion surface can be present on the frontside of the aluminosilicate glass or on the back side of thealuminosilicate glass. The polymer layer can be at least one polyvinylbutyral (PVB) layer having a white appearance, and can be laminated tothe layer of the aluminosilicate glass as a cladding layer. The at leastone PVB layer was not optimized to reduce scattering in this case. Thepolymer layer in the second illustrative example provided a more true“white” color, which may be preferred for providing luxurious ambience,for example, in an automobile.

The opaque matrix material layer 130 can include additional sheet ofglass located on the opposite side of the polymer layer. The additionalsheet of glass may have a desirable optical finish such as an anti-glarefinish.

The surface display unit of the second illustrative example providesless scattering from the front side (and also less scattering whenviewed from the back side). The surface display unit of the secondillustrative example shows a halo effect due to minor reflection peaks(which have lower intensity).

Although the foregoing refers to particular preferred embodiments, itwill be understood that the disclosure is not so limited. It will occurto those of ordinary skill in the art that various modifications may bemade to the disclosed embodiments and that such modifications areintended to be within the scope of the disclosure. Where an embodimentemploying a particular structure and/or configuration is illustrated inthe present disclosure, it is understood that the present disclosure maybe practiced with any other compatible structures and/or configurationsthat are functionally equivalent provided that such substitutions arenot explicitly forbidden or otherwise known to be impossible to one ofordinary skill in the art.

It is also to be understood that, as used herein the terms “the,” “a,”or “an,” mean “at least one,” and should not be limited to “only one”unless explicitly indicated to the contrary. Thus, for example,reference to “a layer” includes examples having two or more layersunless the context clearly indicates otherwise. Likewise, a “plurality”or an “array” is intended to denote “more than one.”

Ranges can be expressed herein as from “about” one particular value,and/or to “about” another particular value. When such a range isexpressed, examples include from the one particular value and/or to theother particular value. Similarly, when values are expressed asapproximations, by use of the antecedent “about,” it will be understoodthat the particular value forms another aspect. It will be furtherunderstood that the endpoints of each of the ranges are significant bothin relation to the other endpoint, and independently of the otherendpoint.

The terms “substantial,” “substantially,” and variations thereof as usedherein are intended to note that a described feature is equal orapproximately equal to a value or description. For example, a“substantially uniform” surface is intended to denote a surface that isuniform or approximately uniform.

Unless otherwise expressly stated, it is in no way intended that anymethod set forth herein be construed as requiring that its steps beperformed in a specific order. Accordingly, where a method does notactually recite an order to be followed by its steps or it is nototherwise specifically stated in the claims or descriptions that thesteps are to be limited to a specific order, it is no way intended thatany particular order be inferred.

While various features, elements or steps of particular embodiments maybe disclosed using the transitional phrase “comprising,” it is to beunderstood that alternative embodiments, including those that may bedescribed using the transitional phrases “consisting” or “consistingessentially of,” are implied. Thus, for example, implied alternativeembodiments to a method that comprises A+B+C include embodiments where amethod consists of A+B+C and embodiments where a method consistsessentially of A+B+C.

1. A surface display unit comprising: an image panel configured toprovide an optical image on a front surface thereof; and an opaquescreen disposed over the front surface of the image panel, wherein theopaque screen comprises an opaque matrix material layer that transmitslight, reflects light or transmits and reflects light from the imagepanel, wherein the opaque matrix material layer comprises one or both ofan electrochromatic material layer and a photochromatic material layer.2. The surface display unit of claim 1, wherein the opaque matrixmaterial layer attenuates light impinging thereupon from a front side ofthe opaque matrix material layer and transmits light from the imagepanel.
 3. The surface display unit of claim 1, wherein the opaque matrixmaterial layer further comprises an opaque glass-ceramic material. 4.The surface display unit of claim 1, wherein the opaque matrix materiallayer is provided as a single sheet or as a laminate structurecomprising multiple layers.
 5. The surface display unit of claim 1,wherein the opaque matrix material layer further comprises a glass corewith at least one optically opaque cladding thereupon.
 6. The surfacedisplay unit of claim 1, wherein the opaque matrix material layercomprises a material having one or more peaks in a transmissioncoefficient as a function of wavelength within a range from 400 nm to800 nm.
 7. The surface display unit of claim 6, wherein multiple peaksare present in the transmission coefficient, and correspond towavelengths of illumination radiation of the optical image formed at theimage panel.
 8. The surface display unit of claim 1, wherein the opaquematrix material layer comprises a material having at least two statescorresponding to different transmission coefficients.
 9. The surfacedisplay unit of claim 8, wherein a ratio of a first transmissioncoefficient for an off-state to a second transmission coefficient for anon-state is in a range from 0.001 to 0.5 with a wavelength range from400 nm to 800 nm.
 10. The surface display unit of claim 1, wherein theimage panel comprises a display unit that generates an image employing asingle illumination source.
 11. The surface display unit of claim 1,wherein the image panel comprises a pixilated display device or adisplay panel including a plurality of micro light emitting diodesprovided in an array pattern.
 12. The surface display unit of claim 1,wherein the optical image is transmitted from the image panel throughthe opaque screen to a viewer.
 13. The surface display unit of claim 1,further comprising a projection source for emitting an image onto theopaque screen.
 14. The surface display unit of claim 13, wherein theimage is reflected from the front surface to a viewer.
 15. The surfacedisplay unit of claim 1, wherein the image panel has multiple brightnesssettings to provide different amount of illumination.
 16. The surfacedisplay unit of claim 1, wherein the image panel has a color weightedbrightness adjustment system to compensate for a non-uniformtransmission coefficient curve of a material of the opaque matrixmaterial layer within a visible wavelength range.
 17. The surfacedisplay unit of claim 1, wherein the surface display unit has comprisesoptical features that limit a viewing angle, the optical features beingselected from gratings and an array of reflective surfaces.
 18. Asurface display unit comprising: an image panel configured to provide anoptical image on a front surface thereof; and an opaque screen disposedover the front surface of the image panel, wherein the opaque screencomprises an opaque matrix material layer that transmits light, reflectslight or transmits and reflects light from the image panel, wherein theopaque matrix material layer further comprises a dye-sensitized materiallayer.
 19. The surface display unit of claim 18, wherein the opaquematrix material layer comprises a material having one or more peaks in atransmission coefficient as a function of wavelength within a range from400 nm to 800 nm.
 20. The surface display unit of claim 19, wherein aratio of a first transmission coefficient for an off-state to a secondtransmission coefficient for an on-state is in a range from 0.001 to 0.5with a wavelength range from 400 nm to 800 nm.